US5693685A - Thermal insulator and method for producing the same - Google Patents

Thermal insulator and method for producing the same Download PDF

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US5693685A
US5693685A US08/638,308 US63830896A US5693685A US 5693685 A US5693685 A US 5693685A US 63830896 A US63830896 A US 63830896A US 5693685 A US5693685 A US 5693685A
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gas
thermal insulator
closed
cells
compound
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US08/638,308
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Yoshio Kishimoto
Masa-aki Suzuki
Takashi Hashida
Fumihiro Inagaki
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Panasonic Holdings Corp
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Matsushita Electric Industrial Co Ltd
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Priority claimed from JP5198133A external-priority patent/JP2746069B2/ja
Priority claimed from JP20624393A external-priority patent/JP2538181B2/ja
Priority claimed from JP6023933A external-priority patent/JPH07233896A/ja
Application filed by Matsushita Electric Industrial Co Ltd filed Critical Matsushita Electric Industrial Co Ltd
Priority to US08/638,308 priority Critical patent/US5693685A/en
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/0066—Use of inorganic compounding ingredients
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/08—Processes
    • C08G18/0804—Manufacture of polymers containing ionic or ionogenic groups
    • C08G18/0809—Manufacture of polymers containing ionic or ionogenic groups containing cationic or cationogenic groups
    • C08G18/0814—Manufacture of polymers containing ionic or ionogenic groups containing cationic or cationogenic groups containing ammonium groups or groups forming them
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/08—Processes
    • C08G18/088—Removal of water or carbon dioxide from the reaction mixture or reaction components
    • C08G18/0885—Removal of water or carbon dioxide from the reaction mixture or reaction components using additives, e.g. absorbing agents
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0025—Foam properties rigid
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2110/00—Foam properties
    • C08G2110/0083—Foam properties prepared using water as the sole blowing agent
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
    • C08J2375/04—Polyurethanes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D2201/00—Insulation
    • F25D2201/10—Insulation with respect to heat
    • F25D2201/14—Insulation with respect to heat using subatmospheric pressure

Definitions

  • the present invention relates to a thermal insulator used for a refrigerator, a freezer, and the like, and a method for producing the same.
  • plastic foams such as a polyurethane foam and a polystyrene foam has been mainly utilized as thermal insulators for refrigerators and freezers. Most of these foams are closed-celled foams. Superior thermal insulators have been produced by using, as a blowing agent for forming cells, chlorofluorocarbon gas having satisfactory blowing properties and low thermal conductivity.
  • a polyurethane foam has been widely used since it can be molded by foaming in place.
  • Japanese Laid-Open Patent Publication No. 2-205582 discloses the use of water-foamed polyurethane as a thermal insulator.
  • the water-foamed polyurethane is obtained as follows: Isocyanate which is a material for polyurethane is reacted with water to form a urea bond and to foam by generating CO 2 gas.
  • a thermal insulator made of polyurethane foam has been used, which utilizes chlorofluorocarbons and water as a blowing agent for the purpose of reducing the amount of chlorofluorocarbons to be used.
  • zeolite which adsorbs CO 2 gas and water vapor in the closed-cells of the polyurethane foam in a thermal equilibrium reaction, is sometimes mixed with the polyurethane foam (e.g., Japanese Laid-Open Patent Publication No. 3-292113 and U.S. Pat. No. 4,882,363).
  • the vacuum insulating panel is obtained by sealing a thermal insulating material in an airtight container and depressurizing so as to decrease thermal conductivity.
  • the vacuum insulating panel has extremely high insulation characteristics.
  • a number of such vacuum insulating panels using the following materials and structures have been proposed. Inorganic fine insulating powders of pearlite, silica, or the like, or a polyurethane foam or a honeycomb structure of open-celled foams are sealed under vacuum as a core material in a container having a high gas barrier property.
  • a metal and plastic laminated film and a plastic multilayer film together with a gas adsorbent have been used.
  • Japanese Laid-Open Patent Publication Nos. 57-133870, 63-21475, and 72293 disclose a vacuum insulating panel in which rigid phenol polyurethane foam is sealed as a core material in a container of a metal and plastic laminated film.
  • a polyol component and an isocyanate component are used as materials for a polyurethane foam.
  • the isocyanate component include diphenylmethane diisocyanate (MDI), tolylene diisocyanate (TDI), and modified compounds thereof.
  • the polyol component include polyetherpolyol and polyesterpolyol.
  • polyhydric alcohol such as polypropylene glycol with cyclic ether such as ethylene oxide
  • those materials are modified (e.g., U.S. Pat. No. 4,309,532).
  • thermal insulators using chlorofluorocarbons having low thermal conductivity is regulated because of its environmental disruption such as the destruction of the ozone layer and the warming of the earth's atmosphere (greenhouse effect).
  • environmental disruption such as the destruction of the ozone layer and the warming of the earth's atmosphere (greenhouse effect).
  • alternate chrolofluorocarbon blowing agent has been conducted.
  • study of an insulating foam without using chlorofluorocarbons as a blowing agent has been conducted.
  • the inventors of the present application has noticed that the conventional foam in which zeolite powders are dispersed (e.g., Japanese Laid-Open Patent Publication No. 3-292113) has the following various problems.
  • the CO 2 gas reducing function of zeolite is based on an adsorption-desorption equilibrium reaction. Therefore, zeolite can not remove the CO 2 gas sufficiently.
  • zeolite adsorbs water as well as the CO 2 gas, so that zeolite powders dispersed in a polyurethane foam using water for a foaming reaction adsorbs water and cannot sufficiently adsorb the CO 2 gas.
  • the adsorption rate of CO 2 gas by zeolite is relatively high, therefore the CO 2 gas generated by the reaction of water and isocyanate cannot function sufficiently as a blowing agent. Therefore, it is essential to use another blowing agent such as chlorofluorocarbon used in Japanese Laid-Open Patent Publication No. 3-292113.
  • a foam having depressurized cells has a problem in that air penetrates to the depressurized cells with time when the barrier property of the container of the foam is low, resulting in the decrease in thermal insulation characteristic.
  • a high nitrile ABS plastic having a high barrier property is used as a material for the container in Japanese Laid-Open Patent Publication No. 3-292113.
  • the thermal insulator having the above structure has a problem in that the thermal insulation characteristic is remarkably decreased when pin-holes are formed in the container.
  • the vacuum insulating panel is excellent in insulation characteristics but has some problems. While a thermal insulator obtained by foaming polyurethane in place can be easily injected into housings with various shapes, the vacuum insulating panel has a predetermined shape, requiring an additional step of attaching the vacuum insulating panel to a housing.
  • the container for the vacuum insulating panel is required to have low gas permeability, and in order to suppress the increase in gas in the container, an adsorbent excellent for adsorbing gas is required.
  • the thermal insulator of this invention comprises a foam containing solidified CO 2 gas.
  • the foam is a closed-celled foam including depressurized closed-cells.
  • the closed-celled foam is a water-foamed rigid polyurethane.
  • the solidified CO 2 gas is a metal salt selected from the group consisting of a metal carbonate and a metal hydrogencarbonate.
  • the metal salt is a thermally stable metal salt.
  • the thermally stable metal salt comprises an alkaline-earth metal selected from the group consisting of a calcium salt, a barium salt, and a magnesium salt.
  • the closed-celled foam comprises a plastic having a free amino group, a metal compound selected from the group consisting of a metal halide and a metal phosphate, and a metal carbonate.
  • the free amino group is a lysine.
  • the solidified CO 2 gas comprises an alternant copolymer of an epoxide compound and CO 2 gas.
  • the alternative copolymer comprises, as a copolymerization catalyst, a compound of metal selected from the group consisting of zinc, cobalt, aluminum, and tin.
  • the copolymerization catalyst is selected from the group consisting of a mixture of an organic zinc compound and a compound having active hydrogen with at least two valences, an organic zinc compound carried on a metal oxide, an aliphatic zinc carboxylate, and a zinc halide carried on a metal oxide.
  • the closed-celled foam is filled in a housing having a metallic outer housing and a resinous inner housing.
  • the foam containing the solidified CO 2 gas is filled in a sealed air-tight container.
  • the foam is a closed-celled foam.
  • a method for producing a thermal insulator comprising a foam including depressurized cells comprises the steps of: generating a foam including cells containing CO 2 gas; and
  • the foaming step is a step of generating a closed-celled foam made of a water-foamed polyurethane.
  • a method for producing a thermal insulator further comprises the step of:
  • a metal compound selected from the group consisting of a metal oxide and a metal hydroxide, water, a polyol component, and an isocyanate component to generate a mixture
  • the foaming step is a step of foaming the mixture in a container to generate a closed-celled foam made of a water-foamed polyurethane
  • the solidifying and depressurizing step is a step of allowing CO 2 gas generated during the foaming step to react with the metal compound to solidify the CO 2 gas, thereby depressurizing closed-cells in the closed-celled foam.
  • the polyol component is selected from a polyol component having an ammonium halide branched structure and a polyol component having an ammonium phosphate structure;
  • the foaming step is a step of generating a closed-celled water-foamed polyurethane having an ammonium halide branched structure
  • the solidifying and depressurizing step includes the steps of: allowing a free amino group generated by the reaction between the ammonium halide branched structure and the metal compound to react with CO 2 gas generated in the foaming step; and allowing the obtained compound to react with metal ions of the metal compound to solidify the CO 2 gas, thereby depressurizing the closed-cells in the closed-celled foam.
  • the polyol component contains a compound selected from the group consisting of diol having an ammonium halide branched structure and diamine having an ammonium halide branched structure.
  • the mixing step comprises the step of dispersing the metal compound in a liquid selected from the group consisting of water, a polyol component, and a mixture of water and the polyol component.
  • a method for producing a thermal insulator further comprises the step of mixing an epoxide compound, a copolymerization catalyst, water, a polyol component, and an isocyanate component to generate a mixture,
  • the foaming step is a step of foaming the mixture in a container to generate closed-celled foam made of a water-foamed polyurethane
  • the solidifying and depressurizing step is a step of allowing CO 2 gas generated during the foaming step to be alternatively copolymerized with the epoxide compound to solidify the CO 2 gas, thereby depressurizing the closed-cells in the closed-celled foam.
  • the mixing step comprises a step of previously mixing the epoxide compound with the copolymerization catalyst.
  • the epoxide compound has a boiling point of 65° C. or less.
  • the container used during the foaming step is an air-tight container
  • the solidifying and depressurizing step is a step of solidifying CO 2 gas generated during the foaming step, thereby depressurizing the container as well as cells in the foam.
  • the invention described herein makes possible at least one of the advantages of (1) providing a thermal insulator made of closed-celled foams with high insulation characteristic capable of being molded into many shapes; (2) providing a thermal insulator whose high insulation characteristic can be maintained for a long period of time without decreasing the degree of depressurization of the closed-cells; and (3) providing a method for producing a vacuum thermal insulator from a foamed plastic capable of being produced by forming in place, without a step of depressurizing using a vacuum pump and a step of attaching of the insulator as required in the conventional example.
  • FIG. 1 is a cross section view showing an exemplary construction of a thermal insulator according to the present invention.
  • FIG. 2 is a cross section view showing an exemplary construction of a thermal insulator according to the present invention provided in a housing of a refrigerator.
  • FIG. 3 is a graph showing the producing step of a foam used in a thermal insulator according to the present invention.
  • the present invention relates to a thermal insulator made of a foamed plastic containing a solidified CO 2 gas.
  • the solidification of the CO 2 gas refers to the reaction in which the CO 2 gas is reacted to generate a metal salt compound or in which the CO 2 gas is polymerized to generate a plastic.
  • the adsorption of the CO 2 gas by an adsorbent such as zeolite is an equilibrium reaction (reversible), so that the CO 2 gas cannot be sufficiently removed.
  • the solidification of the CO 2 gas according to the present invention is a non-equilibrium reaction (irreversible at the normal temperature). Accordingly, the CO 2 gas is removed sufficiently.
  • the solidification of the CO 2 gas in the foam used for the thermal insulator according to the present invention is not decreased due to the presence of water, even though water-foamed polyurethane is used for the thermal insulator, the CO 2 gas is effectively solidified.
  • metal salt compounds obtained by solidifying the CO 2 gas are as represented by the following Formulae (1) to (4).
  • metal ions are reacted with the CO 2 gas to form a carbonate having high thermal stability.
  • calcium carbonate is dissociated at a temperature higher than about 900° C.
  • a metal oxide or a metal hydroxide excellent solidifying agents, reacts with the CO 2 gas to form a metal carbonate or a metal hydrogencarbonate.
  • suitable metal salts include those containing alkaline-earth metal.
  • a calcium salt, a barium salt, and a magnesium salt are the most suitable.
  • M indicates a metallic element
  • x and y are integers.
  • the metal oxide is likely to react with water to form a metal hydroxide as represented by Formula (2).
  • the metal hydroxide is reacted with the CO 2 gas to generate a metal carbonate and water as represented by Formula (3).
  • the water is reacted with isocyanate to form polyurethane having a urea bond and simultaneously to generate the CO 2 gas, which functions as a blowing agent, as represented by the following Formula (5).
  • the CO 2 gas is reacted with a metal oxide or a metal hydroxide to be solidified, resulting in a metal carbonate or a metal hydrogencarbonate, as described above.
  • the CO 2 gas in the plastic foam is solidified and thus, the cells are depressurized.
  • Representative examples of a system which solidifies the CO 2 gas to generate a metal salt compound includes a plastic having a free amino group.
  • the solidification of the CO 2 gas refers to a reaction in which metal ions are reacted with the CO 2 gas to form a metal carbonate.
  • suitable metal salts include those having alkaline-earth metal such as a calcium salt, a barium salt, and a magnesium salt. Among them, the calcium ions are the most suitable.
  • the following Formulae (6) to (9) represent the reaction of the calcium ions.
  • the reaction of forming a metal carbonate in the plastic foam having a free amino group has a feature of enhancing the solidification of the CO 2 gas. More specifically, in a medium having a free amino group, the CO 2 gas in the cells is efficiently solidified to form a metal carbonate or a metal hydrogencarbonate as represented by Formulae (6) to (9).
  • the above-mentioned reaction is similar to a biomineralization mechanism in which a shellfish itself synthesizes a mineral such as a shell in a living body system.
  • CO 2 taken from sea water is first absorbed as ammonium carbonate in a medium (biomembrane) having a lysine of a protein, which is a free amino group, in a high concentration, and the ammonium carbonate is reacted with calcium ions to be solidified as calcium carbonate, as represented by Formula (11).
  • the biomineralization mechanism calcium ions or carbonic acid ions are efficiently condensed to form a calcium carbonate mineral in a space formed by organic substances.
  • the present invention uses a similar reaction to that of the biomineralization mechanism to efficiently solidify CO 2 .
  • the water generated in the above reaction is reacted with isocyanate to form polyurethane having a urea bond as represented by Formula (5), and simultaneously to generate CO 2 gas. Furthermore, the CO 2 gas is reacted with a metal salt compound to be solidified, resulting in a metal carbonate or a metal hydrogencarbonate.
  • a representative example of the plastic obtained by solidifying the CO 2 gas is polycarbonate.
  • the CO 2 gas which has been generated by the reaction of Formula (5) and has functioned as a blowing agent, is resinified by alternant copolymerization reaction with the epoxide compound.
  • CO 2 gas and an epoxide compound generate polycarbonate by alternant copolymerization reaction as shown in Formula (14).
  • This reaction is easily effected at room temperature in the presence of a copolymerization catalyst such as a metal compound.
  • a copolymerization catalyst such as a metal compound.
  • the CO 2 gas is subjected to alternative copolymerization reaction in the closed-cells of the foamed plastic to be solidified as polycarbonate resin.
  • the reaction of the CO 2 gas in the foamed plastic is effected, so that the CO 2 gas in the cells are removed, and the cells are depressurized.
  • the epoxide compound having a boiling point of about 65° C. or less the epoxide compound is vaporized by heat generated by the reaction between the polyol component and the isocyanate component to function as a blowing agent. Thereafter, the epoxide compound is reacted with the CO 2 gas. Therefore, the decrease in a vapor component in the cells is promoted, and the cells are more efficiently depressurized.
  • the thermal insulator of the present invention has a function of solidifying the CO 2 gas working as a blowing agent.
  • a vacuum insulating panel can be formed without depressurizing by using a vacuum pump or the like.
  • closed-celled foams are formed according to the present invention, the closed-cells are depressurized.
  • a vacuum insulating foam having closed-cells which are depressurized can be obtained.
  • the "closed-celled foam” used in the present specification refers to a foam having a percentage of closed-cells of 80% or more measured by Air Pycnometer.
  • the thermal insulator of the present invention has the following many excellent effects and hence is industrially valuable.
  • a vacuum insulating panel can be produced without the steps of depressurizing by using a vacuum pump or the like as conducted in the conventional example, a core material is not required to be formed into open-celled foams as in the conventional example, and a vacuum insulating panel made of a closed-celled foam with high insulation characteristic can be obtained.
  • the resultant thermal insulator can be made flame-retardant.
  • a thermal insulator of the present invention includes a foamed plastic 2 having closed-cells, and metal carbonate 3 obtained by solidifying CO 2 gas with a metal oxide (or a metal hydroxide) in a container 1.
  • the CO 2 gas forms closed-cells during the polymerization of a material for the foamed plastic 2. Thereafter, the CO 2 gas is reacted with the metal oxide (or metal hydroxide) to be solidified, resulting in the metal carbonate 3. At this time, the closed-cells are depressurized. For this reason, the foamed plastic 2 is required to be a rigid foamed plastic which is not greatly deformed when the closed-cell in the foam is depressurized.
  • Preferred examples of the material for the foamed plastic 2 include polyurethane, polystyrene, and polyvinylidene chloride.
  • Water-foamed polyurethane having a urea bond is the most suitable.
  • the water-foamed polyurethane is obtained as follows: Isocyanate which is a material for polyurethane is reacted with water to form a urea bond and to generate CO 2 gas which functions as a blowing agent.
  • a cross-linker can be contained in the material for the foamed plastic 2.
  • the cross-linker cross-links the foamed plastic 2 to enhance its hardness and resistance to deformation under heat.
  • the cross-linker include compounds having a cross-linking functional group, such as aldehyde, epoxide, isocyanate, and chlorosilane. These compounds produces a cross-linking structure by forming a methylene bond, an epoxy bond, a urethane bond, a urea bond, an allophanate bond, abiuret bond, and an acid amide bond. In the case where these compounds generate reaction gas during the cross-linking reaction, it is required to add an adsorbent for adsorbing the reaction gas so as not to decrease the degree of depressurization in the cells.
  • a method for producing a thermal insulator of the present invention includes the steps of: mixing a metal oxide or a metal hydroxide, water, a polyol component, and an isocyanate component; foaming the mixture in a container to generate a water-foamed polyurethane with closed-cells having a urea bond; and allowing CO 2 gas generated in the foaming step to react with the metal oxide or the metal hydroxide in the closed-cells to be solidified, resulting in a metal carbonate or a metal hydrogencarbonate.
  • the closed-cells are depressurized.
  • a dispersion solution in which a metal oxide is previously dispersed in a polyol or a dispersion solution in which a metal hydroxide is previously dispersed in water, a polyol, or a mixture of water and a polyol.
  • the polyol component is prepared by adding the above-mentioned cross-linker, a foam stabilizer, a urethane reaction catalyst, or the like.
  • the polyol component high molecular weight compounds having at least two reactive hydrogen atoms are used. Polyester polyol and polyether polyol are preferred.
  • isocyanate component compounds having at least two isocyanate groups are used. Tolylenediisocyanate, crude diphenylmethanediisocyanate, or an isocyanate mixture or organic polyisocyanate based on these compounds are generally used.
  • a foam stabilizer, a urethane reaction catalyst, or the like can be added to the above-mentioned components. If required, an antioxidant, a flame retardant, a filler, or the like can be added, provided that it is required to select these additives so as not to volatilize under reduced pressure after the foaming step.
  • foam stabilizer examples include an organic silicone type surfactant, an aliphatic metal salt, an aliphatic metal sulfonate, and paraffin oil.
  • the organic silicone type surfactant is preferably used.
  • the urethane reaction catalyst examples include organic tin type compounds, organic lead type compounds, and highly basic amine type catalysts. The amine type catalysts are preferably used.
  • CO 2 gas thoroughly dissolves in water, so that a high-pressure carbonic acid solution can be used as a blowing agent.
  • the CO 2 gas is generated by the water foaming reaction of isocyanate which is a material for polyurethane.
  • isocyanate is a material for polyurethane.
  • CO 2 for general foaming can also be used as the blowing agent used in the present invention.
  • As the CO 2 used for general foaming liquefied CO 2 and CO 2 in a super-critical fluid state are used.
  • the thermal insulator of the present invention is obtained by forming a plastic foam, which has a function of producing a depressurized state in the plastic foam, as a core material in a container.
  • a plastic foam which has a function of producing a depressurized state in the plastic foam
  • a deformable container made of material with a high barrier property is placed in a mold with a suitable shape and a core material in the container is foamed by heating to obtain a foamed structure, resulting in a vacuum insulating panel.
  • the core material can also be foamed by heating in a rigid sealable container having a metal layer with a suitable shape to obtain another type of vacuum insulating panel.
  • the thermal insulator of the present invention is suitable for use in an insulating housing for an electric refrigerator.
  • the thermal insulating foam of the present invention is filled in a sealable refrigerator housing 5 having an injection port 8, including a metallic outer housing 6 and a plastic inner housing 7, an electric refrigerator with excellent insulation characteristics can be constructed.
  • the thermal insulator of the present invention is made of a closed-celled plastic foam 9 having a free amino group
  • the wall surface of the closed-cells 10 of the foamed plastic 9 contains a metal halide or a metal phosphate and metal carbonate 11 solidified by reacting with the CO 2 gas in the closed-cells 10.
  • compounds having a free amino group various kinds of compounds can be used.
  • a lysine structure of polypeptide (--(CH 2 ) 3 CH 2 NH 2 ) is suitable for the present invention.
  • the plastic having a free amino group used in the present invention is required to be a rigid plastic foam which is not greatly deformed by being depressurized.
  • a method for producing a thermal insulator made of a closed-celled plastic foam having a free amino group of the present invention is as follows:
  • a metal oxide or a metal hydroxide, water, a polyol component selected from the group consisting of a polyol component having an ammonium halide structure and a polyol component having an ammonium phosphate structure, and polyisocyanate are mixed.
  • the mixture is injected into a container and reacted to generate a water-foamed rigid polyurethane having a urea bond with an ammonium halide branched structure.
  • the ammonium halide branched structure is reacted with the metal oxide or the metal hydroxide to generate a metal halide or metal phosphate and a free amino group.
  • the CO 2 gas in the closed-cells generated during the molding of the polyurethane is adsorbed by the free amino group, and the adsorbed CO 2 gas is reacted with metal ions of the metal oxide or the metal hydroxide to generate a metal carbonate.
  • the CO 2 gas is solidified and a thermal insulator in which the cells are depressurized is produced.
  • the polyol components having an ammonium halide or an ammonium phosphate structure refers to a polyol having an ammonium halide or ammonium phosphate and a composition of a polyol and an organic ammonium halide or ammonium phosphate.
  • dioxyalkyl tertiary amine has a reaction catalytic function and is effectively polymerized.
  • the dioxyalkyl tertiary amine has a trialkyl tertiary amine structure where two alkyl groups are substituted by hydroxyl (--OH) groups and the other alkyl group is substituted by an ammonium halide structure such as a lysine.
  • an auxiliary additive also functions as a cross-linker and a chain extender.
  • a dispersion solution in which a metal oxide coated with a hot melt coating is previously dispersed in water, a polyol component having an ammonium halide or an ammonium phosphate structure, or a polyol mixture having water and an ammonium halide structure.
  • a thermal insulator of the present invention in which a compound obtained by solidifying the CO 2 gas is a copolymer with an epoxide.
  • a polyol component, water, an epoxide, a copolymerization catalyst, and an isocyanate component are mixed and reacted to generate a foamed polyurethane.
  • the CO 2 gas generated by the reaction between isocyanate and water, and the epoxide compound form an alternative copolymer by the copolymerization catalyst.
  • the CO 2 gas is resinified and the cells are depressurized.
  • epoxide compound of the present invention compounds having one or two epoxy groups, an oxetane derivative, and a tetrahydrofuran derivative are preferred.
  • the epoxy compounds having one epoxy group those having a boiling point of about 65° C. or less function as a blowing agent. Examples of such compounds include ethylene oxide (11° C.), propylene oxide (34° C.), 1,2-epoxybutane (63° C.), cis-2,3-epoxybutane (60° C.), trans-2,3-epoxybutane (54° C.), and butadiene monoxide (65° C.).
  • the temperatures shown in parentheses are boiling points.
  • epoxy compounds having one epoxy group include alkylene oxide compounds such as epoxyhexane, epoxyoctane, epoxydecane, epoxydodecane, epoxyhexadecane, and epoxyoctadecane.
  • compounds having an epoxy group and a double bond unsaturated group such as epoxyhexene and epoxyoctene; compounds having a glycidyl group such as glycidyl methyl ether, glycidyl isopropyl ether, glycidyl acrylate, and phenyl glycidyl ether; and aromatic epoxide compounds such as epoxypropylbenzene and styrene oxide can be used.
  • compounds having two epoxy groups such as diepoxybutane and diepoxyoctane, oligomers having various epoxy groups at both terminals, oxetane having a boiling point of 50° C., and derivatives thereof can be used.
  • the thermal insulator can be flame-retardant.
  • metal compounds such as zinc, cobalt, aluminum, and tin are suitable.
  • a mixture of an organic zinc compound and a compound having hydrogen with two or more valences, organic zinc compounds holding a metal oxide, zinc acetate, a reaction mixture of zinc hydroxide and aliphatic dicarboxylic acid, and zinc halide holding a metal oxide are suitable as the copolymerization catalyst.
  • dialkyl zinc such as diethyl zinc is preferred.
  • compounds having divalent or more of active hydrogen water, primary amine, divalent alcohol, aromatic dicarboxylic acid, aromatic hydroxycarboxylic acid, and the like are suitable.
  • metal oxide holding a zinc compound silicon oxide, aluminum oxide, titanium oxide, and the like are used.
  • a metal hydroxide such as magnesium oxide can also be used.
  • the copolymerization of the CO 2 gas and the epoxide compound is effected even when all of the materials are simultaneously mixed.
  • the epoxide compound by previously mixing the epoxide compound with the copolymerization catalyst, catalytic activity is enhanced and copolymerization proceeds at a high yield.
  • polycarbonate is formed after the formation of foamed plastic. Therefore, the epoxide compound is placed in a microcapsule and is expanded and ruptured by reaction heat, and thereafter, polycarbonate can be formed.
  • FIG. 3 The production step of an insulating foam used in a thermal insulator according to the present invention will be described with reference to FIG. 3.
  • the changes with time in volume of the foam line A
  • conversion of polymerization reaction of a plastic foam line B
  • content of CO 2 gas in cells of the plastic foam using a solidifying agent of the present invention line C
  • content of CO 2 gas in cells of the plastic foam using conventional zeolite line D
  • the values of the changes are normalized by the maximum value of each parameter, respectively.
  • the production step includes a mixing step, a foaming step, a curing step, and a depressurizing step.
  • the depressurizing step according to the invention is a solidifying and depressurizing step.
  • the foaming step the volume of the plastic foam (line A) increases by CO 2 gas generated by a foaming reaction.
  • the conversion of the polymerization of the plastic foam increases.
  • the polymerization reaction proceeds after the foaming step. This step is called the curing step.
  • the plastic foam is completely polymerized and the plastic foam obtains enough mechanical strength.
  • the depressurizing step follows the foaming step.
  • the beginning of the depressurizing step depends on the relation between the rate of foaming and that of reducing the CO 2 gas in the cell.
  • Typical durations of each step of the production step according to the present invention are as follows.
  • the duration of the foaming step is in the order of several minutes.
  • the duration of the curing step is in the order of several hours.
  • the duration of the solidifying and depressurizing step is in a range of ten hours to several days. These step durations depend on the scale of a system.
  • the rate of changes in the CO 2 gas contents in the cells are very different depending on materials used for reducing the CO 2 gas.
  • the solidifying agent of the present invention reduces the CO 2 gas well after the conversion of the polymerization is increased enough (line C). Therefore, the plastic foam has enough mechanical strength to keep the depressurized cells undeformed.
  • the CO 2 gas functions well as the blowing agent and the obtained plastic foam includes the undeformed depressurized cells.
  • the size of the cells is preferably equal to or less than 500 microns, more preferably in the range of 100 to 300 microns.
  • the density of the plastic foam is preferably equal to or less than 0.5 g/cm 3 , more preferably in the range of 0.02 to 0.05 g/cm 3 .
  • the pressure of the CO 2 gas in the cells is preferably less than several torts, more preferably less than tens of torrs.
  • milk of lime obtained by allowing 26 parts by weight of calcium oxide to partially react with 4.2 parts by weight of water was mixed with 100 parts by weight of polyol, 1.5 parts by weight of organic silicone type foam stabilizer, 3 parts by weight of amine type catalyst, 1 part by weight of antioxidant, and 1 part by weight of flame retardant.
  • the mixture was mixed while stirring with 162 parts by weight of polyisocyanate in a container at 4,000 r.p.m. for 5 seconds.
  • the resultant mixture was poured into a predetermined container to be foamed, thereby obtaining a closed-celled water-foamed polyurethane having a urea bond.
  • the CO 2 gas in the cells generated during the above step reacted with calcium hydroxide to generate calcium carbonate and to be solidified.
  • the cells were gradually depressurized, resulting in an excellent thermal insulator.
  • the water vapor generated at this time reacted with calcium oxide to generate calcium hydroxide and to be solidified.
  • the thermal insulation characteristic of the obtained thermal insulator was measured. This revealed that the thermal conductivity of the obtained thermal insulator was 0.010 mW/(m.K) at 24° C. Compared with the thermal conductivity of water-foamed polyurethane (i.e., 0.026 mW/(m.K) at 24° C.) without using calcium oxide, the thermal insulation characteristic of the obtained thermal insulator represented by the reciprocal of the thermal conductivity was about 2.6 times. Furthermore, the change in thermal insulation characteristic was measured over one month, indicating that the thermal insulation characteristic was not deteriorated with time and rather improved.
  • the CO 2 gas in the cells generated during the above step reacted with calcium oxide to generate calcium carbonate and calcium hydrogencarbonate.
  • the cells were gradually depressurized, resulting in an excellent thermal insulator.
  • the thermal insulation characteristic of the obtained thermal insulator was measured. This revealed that the reciprocal of the thermal conductivity of the obtained thermal insulator was about twice that of a thermal insulator produced by using chlorofluorocarbon R11 (trichlorofluoromethane) as a blowing agent.
  • the CO 2 gas in the cells generated during the above step reacted with magnesium hydroxide to generate magnesium carbonate.
  • the cells were gradually depressurized, resulting in an excellent thermal insulator.
  • the CO 2 gas in the cells generated during the above step reacted with calcium hydroxide to generate calcium carbonate.
  • the cells were gradually depressurized, resulting in an excellent thermal insulator.
  • Calcium hydroxide gradually reacted with an ammonium chloride structure as represented by Formula (13) to generate solid calcium chloride and a free amino group.
  • a CO 2 gas in the closed-cells generated in the above step reacted with calcium hydroxide as represented by Formula (11) with high efficiency in the presence of a free amino group to generate calcium carbonate.
  • the closed-cells were gradually depressurized, resulting in an excellent thermal insulator.
  • the polyurethane foam has flame-retardancy.
  • the thermal insulation characteristic of the obtained thermal insulator was measured. This revealed that the reciprocal of the thermal conductivity of the obtained thermal insulator was about 2.3 times that of a closed-celled water-foamed rigid polyurethane without using calcium hydroxide. Furthermore, the change in thermal insulation characteristic was measured over one month, indicating that the thermal insulation characteristic was not deteriorated with time and rather improved.
  • a polyurethane material similar to that obtained in the above was mixed and injected with a mixing head in a sealable housing for a refrigerator having an injection portion constructed by combining a metallic outer housing with an inner housing made of a rigid plastic.
  • a vacuum insulating panel for an electric refrigerator having a thermal insulator made of a closed-celled water-foamed rigid polyurethane having a urea bond was obtained.
  • the CO 2 gas in the cells generated during the above step reacted with calcium oxide with high efficiency in the presence of a free amino group to generate calcium carbonate and calcium hydrogencarbonate.
  • the cells were gradually depressurized, resulting in an excellent thermal insulator.
  • the thermal insulation characteristic of the obtained thermal insulator was measured. This revealed that the reciprocal of the thermal conductivity of the obtained thermal insulator was 0.010 mW/(m.K) at 24° C. Furthermore, the change in thermal insulation characteristic was measured over one month, indicating that the thermal insulation characteristic was not deteriorated with time and rather improved.
  • a foamed polyurethane thermal insulator was produced by using the same polyol, foam stabilizer, catalyst, polyisocyanate, and chlorofluorocarbon R11 as a blowing agent.
  • This foamed polyurethane thermal insulator had a thermal conductivity of 0.014 mW/(m.K) at average 24° C.
  • the reciprocal of the thermal conductivity of the thermal insulator of the present invention was about 1.4 times that of the comparative thermal insulator.
  • Example 8 In the same way as in Example 8, 5 parts by weight of water, 3 parts by weight of organic silicone type foam stabilizer, and 2 parts by weight of amine type catalyst were mixed to obtain a polyol mixture. Then, a compound containing 51 parts by weight of dodecane oxide as an epoxide compound and, as a copolymerization catalyst, 5 parts by weight of a solid catalyst holding diethyl zinc in a porous silica was mixed with the polyol mixture. Thereafter, 160 parts by weight of polyisocyanate was mixed with the resultant mixture, and poured into a container made of a laminated film with a gas barrier property.
  • the mixture in the container was allowed to be foamed, thereby obtaining closed-celled polyurethane foam having a urea bond.
  • CO 2 gas was generated by the reaction between water and isocyanate, whereby a closed-celled polyurethane foam was formed.
  • the generated CO 2 gas in the cells reacted with dodecane oxide by the copolymerization catalyst to generate an alternative polycarbonate component.
  • the closed-cells were gradually depressurized, resulting in an excellent thermal insulator.
  • liquid polyol 100 parts by weight of liquid polyol, 5 parts by weight of water, 3 parts by weight of organic silicone type foam stabilizer, 1 part by weight of antioxidant, 3 parts by weight of flame retardant, and 1 part by weight of amine type catalyst.
  • the resultant mixture was poured into a container together with 165 parts by weight of polyisocyanate to be foamed, thereby obtaining a foamed polyurethane with fine closed-cells.
  • the CO 2 gas in the cells generated in the above step reacted with diepoxyoctane to generate an aliphatic polycarbonate component.
  • the cells were gradually depressurized, resulting in an excellent thermal insulator.
  • some of the epoxide compound functioned as a hardener and cross-liked the foamed polyurethane to form a thermal insulator having excellent mechanical strength.
  • the reciprocal of the thermal conductivity of the thermal insulator was about 3 times that of a closed-celled water-foamed polyurethane obtained without using the epoxy compound.
  • closed-celled foams were produced.
  • the foams used in the thermal insulator of the present invention are not limited thereto.
  • the foam is not required to be a closed-celled foam.
  • the percentage of closed-cells is preferably at least 30%, and more preferably at least 80%. When the percentage of closed cells is lower than 30%, in the case where pin-holes are formed in the container, the thermal insulation characteristic is rapidly decreased, resulting in poor reliability.
  • the percentage of closed-cells can be controlled by the known method in the same way as in the conventional foam.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Inorganic Chemistry (AREA)
  • Polyurethanes Or Polyureas (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
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JP5198133A JP2746069B2 (ja) 1993-08-10 1993-08-10 発泡断熱体およびその製造方法
JP5-198133 1993-08-10
JP20624393A JP2538181B2 (ja) 1993-08-20 1993-08-20 発泡断熱体およびその製造方法
JP5-206243 1993-08-20
JP6023933A JPH07233896A (ja) 1994-02-22 1994-02-22 断熱体とその製造方法
JP6-023933 1994-02-22
US28765994A 1994-08-09 1994-08-09
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US6164030A (en) * 1996-07-29 2000-12-26 Bayer Aktiengesellschaft Fixed vacuum insulation panel
US20050105584A1 (en) * 2002-03-20 2005-05-19 Ngk Insulators Ltd Method of measuring thermal conductivity of honeycomb structure
US11333429B2 (en) 2017-05-23 2022-05-17 Phc Holdings Corporation Refrigeration device

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US5934085A (en) * 1997-02-24 1999-08-10 Matsushita Electric Industrial Co., Ltd. Thermal insulator cabinet and method for producing the same
KR20100125239A (ko) * 2008-03-25 2010-11-30 아사히 가라스 가부시키가이샤 하이드록시 화합물, 그 제조 방법, 그 하이드록시 화합물을 사용한 프리폴리머 및 폴리우레탄
CN102101970A (zh) * 2010-12-17 2011-06-22 深圳职业技术学院 湿固化聚氨酯涂料抑泡剂及其抑泡工艺
CN104163650A (zh) * 2014-07-01 2014-11-26 北京大学深圳研究生院 一种多孔陶瓷及其制备方法
WO2017004465A1 (en) * 2015-06-30 2017-01-05 Grenier Kevin E Composite insulated panels
CN108069660B (zh) * 2017-12-28 2020-09-11 东至安东祥源新型建材有限公司 一种保温砂浆及其制备方法
CN107973620A (zh) * 2017-12-28 2018-05-01 长沙善道新材料科技有限公司 一种无机保温砂浆及其制备方法
CN112225862B (zh) * 2020-10-10 2022-03-11 万华化学集团股份有限公司 一种聚氨酯开孔硬泡组合物、制备方法及应用

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US6164030A (en) * 1996-07-29 2000-12-26 Bayer Aktiengesellschaft Fixed vacuum insulation panel
US20050105584A1 (en) * 2002-03-20 2005-05-19 Ngk Insulators Ltd Method of measuring thermal conductivity of honeycomb structure
US7682072B2 (en) * 2002-03-20 2010-03-23 Ngk Insulators, Ltd. Method of measuring thermal conductivity of honeycomb structure
US11333429B2 (en) 2017-05-23 2022-05-17 Phc Holdings Corporation Refrigeration device

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DE69419464T2 (de) 1999-11-18
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CN1105042A (zh) 1995-07-12
EP0638607A1 (de) 1995-02-15
EP0638607B1 (de) 1999-07-14

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